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Tips for initial Setup / Calibration (Pics Inside)

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I have done almost every tweak I can think of, but I am still not happy with print quality; here is the current output:

https://twitter.com/#!/thepackagegroup/ ... to/1/large


I can't get the PLA to flow consistantly below 210C, this image is at 0.1mm layer height, using Cura RC2 and print run (I am not polling during the print). Yesterday I made some alignment tools, and spent about an hour aligning and lubricating the cross bars and bump stops. The bed is fully level, the printer itself is on printed feet, with felt pads, there is an upgrade fan installed, and now an extruder feeder bearing upgrade.

Current settings are: 0.1mm layer height, 0.8mm wall thickness, 0.8mm bot/top thickness, 25% fill density, 50 mm/s print speed, 150 mm/s travel speed, 210C temperature, and the initial layer is the same height as subsequent layers. I have printed about 15 of these tiny robots, and this is the best combination, at 205C the PLA flow becomes inconsistent.

In terms of print quality, I would be 90% happy if there wasn't the deformation around the 'belt' area, in the front and back - this appears to be a bridging issue, during this section of the print the surface will actually curl upward slightly, so the head drags through it while printing layers. The 'feet' print perfectly, then there's the belt area deformation, then the print improves again with only slight bubbling around the 'chest' area. Is the solution to slowly creep during bridging? If so, how can this be set inside of Cura? When I reduce the layer height to 0.01mm the issue is still present (but reduced, in line with the layer reduction) it never goes away. My filliment is slightly inconsistent, it has ranged from 2.96 to 2.98mm, but I no longer have feed issues, and that wouldn't explain why it occurs while printing this same feature, every time.

Any tips or suggestions? I'm always down to print more robots, maybe creating an ultimaker checkers set in the process ;)

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